Project overview
Rushforth Road Water Treatment Plant (WTP) upgrade project involves the design of a new 16 ML treated water reservoir (TWR), a 1.8 ML chlorine contact tank (CCT) and a new treated water network pumping station (TPS). Rushforth Road WTP is located approximately 11 km south-west of Grafton, New South Wales, and is owned and operated by Clarence Valley Council (CVC).
Rushforth Road WTP plays a vital role in supplying potable water to the Clarence Valley region, servicing communities such as Grafton, Ulmarra, Maclean, Iluka, Yamba, Brooms Head and several surrounding villages. The plant sources raw water from the Nymboida River and Shannon Creek Dam, with additional supply from Karangi Dam.
The existing 32 ML TWR has presented several operational challenges, including cover failures during storms – leading to potential contamination risks – as well as internal short-circuiting and leaks. These issues have resulted in increased operational costs and reduced system efficiency. In response, CVC will decommission the existing reservoir and replace it with a new 16 ML TWR, alongside a dedicated 1.8 ML CCT to improve water disinfection and ensure compliance with regulatory water quality standards.
The system upgrade also includes the construction of a new treated water pumping station and integration with the existing chemical dosing facilities at the WTP. The works will involve the installation of new dosing lines and injection points for chlorine (Cl), fluoride (F) and aqueous ammonia (NH₃(aq)), as well as new water quality monitoring instrumentation. These upgrades aim to enhance chemical dosing control, optimise disinfection contact time and improve overall operational reliability.
Key project stats
Our role
Binnies was engaged by contractor Pensar to deliver the development and ownership of the piping and instrumentation diagrams along with the valve and instrument schedules, as well as the mechanical pipework design of the sample analyser racks, panels and inlet and outlet pipelines in interconnected civil pipework associated with both the 1.8 ML CCT and 16 ML TWR.
In addition, Binnies undertook the computational fluid dynamics modelling for the CCT to ensure optimal plug flow characteristics along with the main plant and sample and dosing system hydraulics.
Upon completion, the project will significantly enhance the resilience, efficiency and performance of the Rushforth Road WTP, securing a safe and reliable water supply for the Clarence Valley community into the future.
- Varying ground conditions across the site, including reactive soils
- Soft water concrete attack
- Integration into existing site infrastructure and dosing systems, including design for changeover during commissioning
- Review of ground investigation data to provide cost-effective remediation and pipeline bedding across the site
- Concrete degradation sensitivity analysis